1998 Operator's Manual
6000
SERIES
FORWARD MOUNT
IMPORTANT - READ CAREFULLY
The Dixon® ZTR® Mower is both easy and fun to operate. However, any
power mower must be operated properly to be safe. It is not a toy or a
recreational vehicle. Before you start to use the mower, read the
operator's manual carefully and become completely familiar with the
controls.
The information in this operator's manual applies to all Dixon
®
ZTR
®
6000 Series Commercial Mowers. Your Dixon dealer will gladly answer
any questions.
See your dealer for warranty service, parts and repairs.
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
Page 2
INDEX
SAFETY .......................................................... Pages 4-9
WARRANTY POLICY .....................................Page 10
SPECIFICATIONS .......................................... Page 11
SEAT ADJUSTMENT INSTRUCTIONS......... Page 12
CONTROLS ....................................................Pages 13-16
OPERATION INSTRUCTIONS ....................... Pages 17-21
CARE AND MAINTENANCE .......................... Pages 22-34
STANDARD SERVICE PARTS LIST .............Page 35
TROUBLESHOOTING ...................................Pages 36-37
6000 Series Forward Mount
Part No. 13090-0700
Page 3
SAFETY
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH
The most common causes of injury to the operator or bystander...
BLADE CONTACT TIP-OVER
BACK-OVERRUNOVER
...read and understand this manual to prevent injuries.
Page 4
SAFETY
SAFETY SYMBOLS
Safety Alert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
Follow recommended safety precautions and safe
operating practices.
Danger
indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Warning
indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
Caution
indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
Page 5
SAFETY
This cutting mower is capable of amputating hands & feet, and throwing objects.
Failure to observe the following safety instructions could result in
serious injury or death.
GENERAL OPERATION:
Read, understand, and follow all instructions in the manual and on the mower before starting.
Only allow responsible adults, who are familiar with the instructions, to operate the mower.
Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade.
Be sure the area is clear of other people before mowing. Stop mower if anyone enters the area.
Never carry passengers.
Do not mow in reverse unless absolutely necessary. Always look down and behind before and while
backing.
Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without
either the entire grass catcher or the deflector in place.
Slow down before turning.
Never leave a running mower unattended. Always turn off blades, set parking brake, stop engine, and
remove key before dismounting.
Turn off blades when not mowing.
Stop engine before removing grass catcher or unclogging chute.
Mow only in daylight or good artificial light.
Do not operate the mower while under the influence of alcohol or drugs.
Watch for traffic when operating near or crossing roadways.
Use extra care when loading or unloading the mower into a trailer or truck. Do not ride the mower when
loading & unloading.
Always wear safety goggles or safety glasses with side shields when operating mower.
Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-
related injuries. These operators should evaluate their ability to operate the riding mower safely enough to
protect themselves and others from serious injury.
Follow the manufacturer's recommendation for wheel weights or counterweights.
Maintain or replace safety and instruction labels, as necessary.
WARNING:
Page 6
The engine exhaust from this product contains chemicals known to the
of California to cause cancer, birth defects or other reproductive harm.
State
SLOPE OPERATION:
Slopes are a major factor related to loss-of-control and tip-over
accidents, which can result in severe injury or death.
SAFETY
All slopes require extra caution.
If you cannot back up the slope or if you feel uneasy on it,
DO
Mow across the slope with your Dixon ZTR - never up or down.
Remove obstacles such as rocks, tree limbs, etc.
Watch for holes, ruts or bumps. Uneven terrain could overturn the mower. Tall
grass can hide obstacles.
Use slow speed. Tires may lose traction on slopes even though the brakes are
functioning properly.
Use extra care with grass catchers or other attachments. These can change the
stability of the mower.
Keep all movement on the slopes slow and gradual. Do not make sudden changes
in speed or direction.
Avoid starting or stopping on a slope. If tires lose traction, disengage the blades and
proceed slowly down the slope.
do not mow it!
If front wheels lift off the ground, pull the levers back to stabilize the mower.
DO NOT
Do not turn on slopes unless necessary, and then, turn slowly and gradually
downhill, if possible.
Do not mow near drop-offs, ditches, or embankments. The mower could suddenly
turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.
Do not mow on wet grass. Reduced traction could cause sliding.
Do not try to stabilize the mower by putting your foot on the ground.
Do not use grass catcher on steep slopes.
Page 7
SAFETY
CHILDREN:
Tragic accidents can occur if the operator is not alert to the
presence of children.
Children are attracted to lawn mowers and the mowing activity.
NEVER assume children will stay where they were last seen.
Be alert to avoid accidents.
Keep children out of the mowing area and under the watchful care
of another responsible adult.
Be alert and turn mower off if a child enters the area.
Before and during backing, look behind and DOWN for small
children.
Never carry children. They may fall off and be seriously injured or
interfere with safe mower operation.
Never allow children to operate the mower.
Use extra care when approaching blind corners, shrubs, trees, or
other objects that may obscure vision.
Page 8
SAFETY
SERVICE:
Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive.
Use only an approved container.
Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling. Do
not smoke.
Never refuel the mower indoors.
Never store the mower or fuel container inside a building where there is an open flame.
If fuel is spilled on clothing, change clothing immediately.
To prevent fire and explosion caused by static electricity:
Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place
containers on the ground away from your vehicle before filling.
When practical, remove gas-powered equipment from the truck or trailer and refuel it on the ground.
If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from
a gasoline dispenser nozzle.
If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete. Do not use a nozzle lock-open device.
Never run a mower inside a closed area. The exhaust fumes are toxic.
Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in good condition.
Never tamper with safety devices. Check their proper operation regularly.
Keep mower free of grass, leaves, or other debris buildup. Clean up oil or fuel spillage. Allow mower to cool
before storing.
Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.
Never make adjustments or repairs with the engine running.
Grass catcher components are subject to wear, damage, and deterioration, which could expose moving
parts or allow objects to be thrown. Frequently check components and replace with original equipment
parts, when necessary.
Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing
them.
Batteries contain sulfuric acid. To prevent burns avoid contact with skin, eyes and clothing. To prevent
a fire or explosion keep sparks and open flames away from battery.
Before disconnecting the negative (-) ground cable, make sure all switches are OFF.
Page 9
DIXON INDUSTRIES, INC.
a BLOUNT company
AIRPORT INDUSTRIAL PARK
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
FAX 316 251 4117
DIXON LIMITED WARRANTY POLICY - COMMERCIAL MODELS
Models 6000 & 7000
WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) years from
date of purchase.
for 1 year from the date of purchase or 400 hours whichever comes first. Commercial use is specified as
use other than, or in addition to, mowing at owner's primary place of residence.
AND WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING
LABOR COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS
1. Warranty applies only to original retail purchaser of new and unused mowers and accessories.
2. All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon warranty
policy and allowances. All warranty claims must be approved by Dixon Industries, Inc.
Commercial Application: Dixon mowers used for commercial application are warranted
DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS
AND LIMITATIONS:
3. Battery warranty: Limited to
4. Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of purchase.
5. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration. The
use of parts or components other than those supplied by Dixon Industries, Inc. VOIDS ALL WARRANTY.
6. The following items are not covered by this warranty policy:
(a) Pick up and delivery charges for transportation of mower to and from an Authorized Dixon
dealer's place of business.
(b) Routine maintenance or adjustments.
(c) Belts/cutting blades/HydroGear filters.
(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each individual engine
manufacturer.
(e) Any costs or expense of providing substitute equipment while repair work is being performed
on a warranted mower.
7. There is no other express warranty. Implied warranties, including those of merchantability and fitness for a
particular purpose, are limited to the same duration of the express warranty, and to the extent permitted
by law any and all implied warranties are excluded. Liabilities for consequential damages under any
and all warranties are excluded.
90 days from date of purchase.
Blue/Customer Ye ll ow/ Dealer Wh ite /D ixo n I nd .
WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this warranty
document, complete the information section below, secure customer's signature &send copy to Dixon Industries, Inc.
DATE OF PURCHASE MODEL S/N
Owner's Name Dealership
Address Address
Owner's Signature Dealer's Signature
Page 10
SPECIFICATIONS
6000 Series Forward Mount
CHASSIS: Sheet metal construction frame
BODY: Folded sheet metal. Seat lifts up for access to battery and belt service.
SEAT: Designed for operator comfort by use of high density closed cell foam
padded back and arm rests, upholstered with CorduraTM water-repellent
fabric. Seat is adjustable fore and aft.
MOWER DECK: 2 Decks are available. 60" & 48" are made of 12 GA fabricated welded
construction with 10 GA reinforcement plate. 3 blades combine for either
a 48" or 60" cut width. Cut height approximately 1" to 5" via 9 position
lift handle.
BLADE DRIVE: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a HydroGear BDU-10L
Series 70 hydrostatic transmission. The hydrostatic transmissions, in
turn, power a fully enclosed HydroGear gearbox.
ENGINE: 22HP Kohler Command, 4-Cycle, V-Configuration, Overhead Valve,
Air-Cooled, Gasoline, Horizontal Shaft, Aluminum Head, and Crankcase
with Cast Iron Liners, Full Pressure Lubrication/Full Flow Filter, Pulsetype Fuel Pump, Fixed Jet Carburetor w/Smart-Choke, Electronic Ignition,
In-Line Fuel Filter, Dual Element Air Cleaner.
STARTING SYSTEM: Electric by key switch operation with safety interlocks on parking brake
and blade drive clutch.
TIRES: Front 4.10x3.50x4
Rear 5.00-6x13
Drive 20-10.0x10
RECOMMENDED Front 16 lbs.
TIRE PRESSURE: Rear 12 lbs.
CAPACITIES: Fuel - 5 gallons
Hydrostat oil tank - 3 quart with in-line 40 micron filter
Hydrostat oil recommendation, refer to page 25
Engine - 2 qts. SAE 10W30 (with filter)
DIMENSIONS: Width 57-1/2(48" Deck), 69-1/2"(60" Deck)
Height 45-1/2"
Length 96" (48 Deck), 101 (60 Deck)
Weight 960 lbs. (48" Deck), 1030 lbs. (60" Deck)
NOTE: Additional information provided in service instructions under the individual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 11
SEAT ADJUSTMENT
INSTRUCTIONS
6000 Series
1. Grasp seat slide adjuster and move it into adjustment
position.
2. Slide seat forward or backward.
3. Release seat slide adjuster.
Page 12
CONTROLS
CONTROL LOCATIONS
Steering Controls
Parking Brake
Lever
Blade Clutch Switch
Ignition Key
Light Switch
Choke
Engine
Throttle
Blade Height
Adjust Lever
Page 13
PARKING BRAKE:
The parking brake is designed to hold the mower from
moving and is not intended for use in stopping the mower
while it is in motion.
CONTROLS
CAUTION
Engage parking brake before starting engine
TO SET PARKING BRAKE:
The hand operated parking brake is located at right hand side
of mower.
To engage brake, pull rearward.
To release brake, move lever forward.
NOTE: Always set parking brake before dismounting.
Release parking brake before moving mower.
HYDRO-GEAR DRIVE SYSTEM:
Allows the mower to turn on its own axis (zero turning radius).
Page 14
Each lever controls one side of the mower.
NOTE: The pressure required to operate the mower is very light.
TO GO FORWARD:
From neutral position, gently push both drive levers forward.
To increase speed, move levers farther forward.
TO GO BACKWARD:
From neutral position, gently pull both drive levers toward you.
CONTROLS
(LEFT TURN OPPOSITE)
TURNING:
Turning is controlled by moving one drive lever slightly forward or rearward of
the other.
To turn left, move left lever rearward of the right lever.
To turn "square corners" move lever of desired direction to neutral.
To turn on mower's own axis (zero turning radius) stop and move one lever to
reverse position and the other to forward position.
BRAKING:
To brake mower, move both levers in direction opposite of travel, release levers
to neutral, set parking brake. Park only on level surfaces.
CHOKE CONTROL LEVER:
Located on control panel to operator's left.
Used to start a cold engine.
THROTTLE CONTROL LEVER:
Located on control panel to operator's right.
Controls engine speed, slow to maximum.
While mowing, throttle control should be set to the MAXIMUM or wide open
setting to insure adequate cooling of the engine and to maintain mower deck
blade speed.
Page 15
BLADE DRIVE:
Located on the control panel to the operator's right.
To engage blades pull switch up.
To disengage blades push switch down.
CIRCUIT BREAKER:
Located on the control panel to the operator's right.
Protection of the electrical system is by (2) 30 amp circuit breakers.
If circuit breaker trips, push button to reset.
If this condition repeats, consult dealer for inspection and repair.
CONTROLS
MOWER DECK CUT HEIGHT LIFT LEVER:
Located to the right and front of the operator.
Controls the cutting height.
Nine positions of adjustment.
Depress trigger and move lever forward to lower deck.
Depress trigger and pull lever back to raise deck.
NOTE: To achieve a 1" to 3" cutting range, the bar connecting the deck lift handle
and the rear of the deck must be in the first hole. To achieve a 3" to 5" range, the bar
connecting the deck lift handle and the rear of the deck must be in the second hole.
NOTE: Always use high position for transport.
Page 16
OPERATION INSTRUCTIONS
The safe and successful operation of the 6000 Series will depend upon the operator
having the correct knowledge of all controls used on the mower and making good
judgements about the terrain to be mowed.
NEVER allow anyone to operate the mower without complete knowledge of all controls
and their functions.
During initial operation, "learning to drive", set throttle at slow speed.
Sound judgement by the owner will prevent accidents.
TOWING
Towing a trailer or other attachment that is too heavy could damage the drive or
cause the mower to become unstable. Limit loads to 500 pounds or less on this
mower.
BEFORE OPERATING MOWER
1. Read engine manufacturer's operating and maintenance
instructions.
2. Discuss proper maintenance with your dealer.
3. Read and observe all safety instructions on your mower
and in the manual.
4. Check engine oil.
5. Check gas cap to be sure it is in place.
6. Be sure parking brake is on.
7. Mower blade drive is off.
8. Know how to stop engine. (Turn key to off position)
Page 17
OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
PARKING BRAKE SWITCH TEST: With parking brake in the ON position,
start the engine. With the engine
running, pull one control lever out of the
neutral position. The engine should
stop. Repeat for the other control lever,
then repeat pulling both control levers
out of neutral at the same time. In all
cases the engine should stop.
BLADE DRIVE SWITCH TEST: (Electric Clutch or Manual Drive)
a. With either electric blade drive switch
turned on, or manual lever turned forward,
parking brake in On position, engine
should not turn over or attempt to start
when key switch is moved to the start
position.
b. In a SAFE AREA away from bystanders,
start the engine, place throttle setting at
maximum or full. Engage the blade drive
either through the electric clutch switch or
by turning the manual lever forward.
Raise weight slightly off of seat. Engine
should stop.
c. If any Safety Check fails, do not operate
the mower until the system has been
checked and repaired by an Authorized
Dixon ZTR Dealer.
Page 18
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS: Cold Engine
1. Push choke control lever fully forward.
2. Push throttle control lever to 1/2 setting.
3. Insert ignition key and turn to "Start" position. When engine starts,
release ignition key. Key will return to "Run" position.
4. Once engine starts to warm up, slowly move choke control lever to the
fully closed position.
5. Move throttle control lever to the wide open or maximum setting for actual
operation of the mower deck.
6. Engine must be operated at wide open or maximum setting to insure
adequate lubrication, cooling and cut quality of the mower deck.
Note: 6000 Series mowers will require a slightly longer warm-up period using
partial choke settings.
UNLOCK TRANSMISSION:
The freewheel levers are located on
each side of the mower below the seat
mount (flip up the foot deck to access
them). Lift the levers slightly, push
them to the rear and down to release
the transmissions for free wheeling. To
engage the transmissions lift the levers
slightly, pull them forward and then
down.
NOTE: The tractor should never be
pulled at more than 2 miles per hour or
for any appreciable distance.
TRANSMISSION
RELEASE VALVE
REAR TIRE
FREEWHEEL LEVER
Page 19
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS: Engine has been operated.
1. Move throttle control lever to 1/4 to 1/2 setting.
2. Insert ignition key and turn to "Start" position. When engine starts,
release ignition key. Key will return to "Run" position.
3. Move throttle control lever to wide open or maximum setting for actual
operation of the mower deck.
NOTE: Model ZTR 6022 may require partial choke setting to start even
if the engine has been operated for a period of time.
4. Engine must be operated at wide open or maximum setting to insure
adequate lubrication, cooling and cut quality of the mower deck.
CAUTION
NOTE: On initial operation, set throttle at slow speed.
DO NOT operate the engine in an enclosed area due to the
harmful exhaust gas produced.
Engine cannot be restarted when blade is engaged.
Safety switches stop engine when operator leaves seat while
mower blade is engaged.
Always turn engine off when leaving mower.
Page 20
OPERATION INSTRUCTIONS
In order to achieve optimum cutting performance, please read and follow the tips listed below.
Additional information can be found in the troubleshooting guide on pages 36-37.
CAUTION
1. Set engine speed control to the wide open or full setting.
2. Do Not Attempt To Cut Grass When It Is Wet. Wet grass will clog the underside of the deck
and discharge area.
3. If the grass is tall, place the mower deck cut height lever in the top or second notch. "Initially"
overlap cutting swaths instead of a full swath with each pass. Some applications may require a
second cutting.
4. Keep The Underside Of The Mower Deck Clean. Frequent removal of dried grass and dirt will
allow the clippings to discharge correctly.
5. Maintain sharp blade(s) throughout the cutting season.
Be sure that deflector is properly installed on the
discharge chute.
GRASS HEIGHT SUGGESTIONS:
Correct mowing height can reduce weeds and disease by 50% to 80%
The following grass cut heights are based on adequate moisture conditions and normal thatch
buildup in a healthy lawn. Some locations and applications may require slightly different cut heights.
If in doubt, consult your local lawn professional for assistance.
Grass Types: Best Cut Heights:
Zoysia 2" - 2 1/2"
Blue Grass 1 1/2" - 3"
Fescue Blends 1 1/2" - 3"
St. Augustine (Mid South) 1 1/2" - 2"
St. Augustine (Deep South) 3" - 4"
Tifton Bermuda 1 1/2"
Centipede 1 1/2" - 2"
Common Bermuda 1 1/2" - 2"
Bahia/Argentina/Pensacola 2"
Page 21
CARE AND MAINTENANCE
CAUTION
Before performing any maintenance, turn off engine, allow to cool, remove key
and disconnect spark plugs. Use extreme care when working on machinery.
Do not wear watch or jewelry. Do not wear loose fitting clothes, and observe
all common safety practices with tools.
MAINTENANCE SCHEDULE
Check drive belts . . . . . . . . . . . . . . . . . . . . . . .
(20 hours break-in)
Check crankcase oil level. . . . . . . . . . . . . . . . . . .before each use
Clean grass from Hydrostat fans and cooling fans . . . . . .before each use
Check air intake screen. . . . . . . . . . . . . . . . . . . . . after each use
Clean grass under deck . . . . . . . . . . . . . . . . . . . . after each use
Check tire pressure . . . . . . . . . . . . . . . . . . . . . . every 10 hours
Check battery fluid . . . . . . . . . . . . . . . . . . . . . . every 10 hours
Sharpen mower blades . . . . . . . . . . . . . . . . . . . . every 10 hours
Check air filter element . . . . . . . . . . . . . . . . . . . . every 25 hours
Check hydrostatic transmission fluid . . . . . . . . . . . . . every 25 hours
Service engine air filter pre-cleaner . . . . . . . . . . . . . . every 25 hours
Grease driveline (3 fittings) . . . . . . . . . . . . . . . . . . every 50 hours
Grease jack shaft . . . . . . . . . . . . . . . . . . . . . . . every 50 hours
Grease deck pivot tube . . . . . . . . . . . . . . . . . . . .every 50 hours
Check adjustment of P.T.O. clutch. . . . . . . . . . . . . . .every 50 hours
(or if blades do not stop with 7
seconds from switch disengagement)
Service air filter element . . . . . . . . . . . . . . . . . . . .every 25 hours
Change engine crankcase oil. . . . . . . . . . . . . . . . .every 100 hours
(5 hours break-in)
Change engine oil filter. . . . . . . . . . . . . . . . . . . . every 100 hours
Change hydrostat oil filter (7252) . . . . . . . . . . . . . . every 500 hours
(50 hours break-in)
Change oil in deck gearbox . . . . . . . . . . . annually or every 500 hours
Replace air filter element. . . . . . . . . . . . . . . . . . . every 100
Check spark plugs. . . . . . . . . . . . . . . . annually or every 200 hours
Service battery . . . . . . . . . . . . . . . . . . annually or every 500 hours
every 50 hours
hours
Note: Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
Replace decals when illegible.
Page 22
ENGINE:
CARE AND MAINTENANCE
For complete maintenance and operating information of the engine, please refer to the
maintenance instructions furnished by the engine manufacturer and included in your Zero
Turn Radius Mower information packet.
Note: Air intake screen must be kept clean. If plugged, engine may be seriously damaged
by over heating.
CAUTION
BATTERY:
Battery electrolyte is a poisonous and corrosive sulfuric
acid solution. Avoid spilling on skin, eyes and clothing.
Check the fluid in the battery at frequent intervals.
Keep fluid level above the plates in each cell, using distilled water.
OFF SEASON BATTERY STORAGE:
Identify each cable so cables can be reconnected to correct terminals.
Disconnect cables from terminals.
ALWAYS disconnect ground cable first and reconnect last.
Charge battery.
DO NOT remove battery from mower.
Clean top of battery and terminals with baking soda and water.
TIRES:
pressure periodically. Inflate tires to the pressure listed below.
Correct tire pressure is essential for efficient operation of the mower. Check tire
Front tires - 16 lbs.
Rear tires - 12 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
Page 23
CARE AND MAINTENANCE
Stop engine, remove ignition key and spark plugs for safety. Wear heavy,
CAUTION
MOWER BLADES:
Check sharpness of mower blades after every 10 hours of operation. To sharpen
blades, proceed as follows.
A. Remove bolt, lock washer, and large flat washer mounting blade on shaft.
B. Blades should be discarded when worn excessively.
C. Sharpen blade with a hand file, electric grinder or blade sharpener. Wear gloves
D. Check balance of blade by positioning the blade on a nail or blade balance
thick gloves when holding onto cutter blade, avoid the sharp
edge of the blade.
Remove blade.
and eye protection when sharpening. Grind blade at original 25 degree bevel.
pedestal. Grind the blade on the end that is heavier until both sides balance.
E. Install blade, flat washer, lock washer and bolt. Make sure to tighten bolt to 60
NEW BLADE
V-BELTS:
The main hydro drive belt should be checked after the first 20 hours and every 50
hours thereafter. Replace any belts found to be in poor condition. The deck belt is
equipped with a spring loaded belt tightener and does not require tightening
adjustments. The hydrostatic transmission belt is adjusted manually (see page 27 for
tensioning instructions).
ft. lbs.
25 Degrees
DANGEROUS!
When notch starts
discard blade
Page 24
CARE AND MAINTENANCE
LUBRICATION:
A. Engine: Follow engine manufacturer's recommendation.
B. Deck spindles: Lubricate with 3 "shots" only, every 100 hours.
C. Hydrostatic transmission and filter.
D. P.T.O. Shaft: Grease every 50 hours.
E. Deck lift rod wldt: Grease every 50 hours.
F. Deck Gearbox: See page 32.
CHECKING & REPLENISHING OIL IN HYDROSTATIC
TRANSMISSION
Hydrostatic
Transmission
Oil Reservoir
Check the oil level in hydrostatic transmission oil reservoir after
every 25 hours of usage. Do not remove the reservoir cap to
check the oil level as this allows dirt to enter the transmission.
Replenish as needed with 20W-50 Mobil Super H.D.
A. Wipe area of oil reservoir cap clean of dirt & debris.
B. Remove oil reservoir cap.
Hydrostatic
Transmission
Filter
C. Fill to line marked on reservoir.
D. Do not overfill.
E. When check oil level be very careful to keep the
reservoir clean and fill only with clean oil.
Change the oil in the reservoir and hydrostat transmission oil
filter after the first 200 hours of use. Then every 500 hours after
that. Remove the filter and be sure all oil has drained from the
reservoir. Replace with new filter and 20W-50 Mobil Super II.
Please dispose of used oil at proper collection centers - protect your environment
Page 25
CARE AND MAINTENANCE
PARKING BRAKE ADJUSTMENT
With the brake handle in the release
position, remove the cotter pin from the
castle nut. Insert a 0.010 feeler gauge
between the brake disc and the brake puck.
Tighten the castle nut with the feeler gauge
inserted until the gauge fits snugly between
the disc and puck. The gap should not be
so tight that the feeler gauge cannot be
reinserted after removal. Back the castle
nut to the closest pin hole and reinsert the
cotter pin. Repeat for other side. See
picture at right.
CASTLE NUT
COTTER PIN
.010 gap between brake
disc and brake puck
HYDROSTATIC TRANSMISSION:
Before each use, check to be sure that the cooling fins of the hydrostatic transmissions are clean.
Excessive accumulation of oil, dirt, or trash may cause the transmission to overheat. NEVER
WASH ACROSS TOP OF RESERVOIR with water or steam. Fill reservoir as required per
instructions page 25 of this manual.
SCALPER ROLLER BOLTS
Scalper roller bolts should be tightened until the spacer bushing will not turn relative to the
scalper bracket to prevent undue wear on the end of the spacer bushing and the scalper
bracket. The proper torque is from 17 to 20 ft. lbs.
Page 26
CARE AND MAINTENANCE
HYDROSTAT DRIVE BELT TENSION ADJUSTMENT
In normal use the hydrostat drive belt tension should be check after the first 20 hours of
use for normal wear in and stretch. It may be adjusted as follows:
A. Loosen the idler pulley locking nut until the idler pulley can be just moved relative to the
mounting bracket.
B. Tighten the tension adjust bolt until the belt is tight enough to prevent belt slippage.
Belt should deflect approximately 3/8" to 5/8" under moderate pressure. Do not over
tighten.
NOTE: If belt is over tightened it will often make a "chattering" noise.
C. Retighten the slide locking nut.
Motor Pulley
Tension Adjust Bolt
Idler Pulley
Cooling Fins
Hydrostatic
Drive Belt
Hydrostatic
Drive Pulley
D. Retighten the tension adjust bolt 1/4 turn to set the lockwasher and prevent loosening
of the tension adjust bolt.
Page 27
CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS
A. To Adjust Neutral:
1. Remove the fender skirts from each side of the machine.
2. Block up the unit so that the Drive Wheels are off the ground.
3. Start the engine and run at a fast idle with the Steering control levers in the "out" position.
4. Loosen the locknuts tightened against the rod end ball joints in the Upper Linkage Assembly.
NOTE: One of these is a left hand nut and will have to be turned backwards.
5. Adjust the Neutral Position by turning the rod in the upper linkage until the wheel stops turning.
6. Retighten the nuts on the Upper Linkage Assembly and check to see that the drive wheel is
still not turning.
7. Repeat steps 1-6 for the other side.
8. Shut off engine before removing the blocks.
B. To Adjust "IN" Position of the Steering Controls:
1. Remove the two front bolts, lockwashers, and washers which hold the fender cap.
2. Pull the boot from the hole in the fender cap, exposing the cast iron lever.
3. Using a 5/32" Allen wrench, turn the setscrew to adjust the stop.
4. Replace the boot into the hole in the fender cap.
5. Replace the two front bolts, lockwashers and washers.
C. To Align Handles:
Sit on the seat and push the control levers full forward and full backward. If the ends do not match the
handles may be adjusted as follows:
1. Locate setscrew stops in the steering control lever base which stop the lever in each direction.
NOTE: The one at the rear is the stop for FWD and the one in the front is the stop for REV.
2. Adjust setscrew stops so that handles line up together when shifted full forward and full reverse.
Page 28
CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS (continued):
D. Adjusting for Straight Forward Tracking:
In large open area, actuate the control handles into the full forward position. If the mower veers in
either direction (left or right) some adjustment is necessary.
1. If the mower veers to the right, then the right hydrostat needs to be sped up. If the
mower veers to the left, then the left hydrostat needs to be sped up.
2. Stop the machine and shut off the engine.
3. Slightly loosen the bolt at the lower end of the upper linkage assembly on the side that
is slower. Using a 1/8" allen wrench turn the setscrew 1/4 turn in. It may take several
test drives to get the mower to track straight forward.
4. Once the tracking is to the operators liking, completely tighten the bolt on the control
linkage, completely tighten the bolt on the control linkage assembly that was loosened
earlier.
5. Recheck to make sure neutral adjust has not been effected, see procedure A.
ACCESS HOLE
FENDER CAP
REVERSE STOP
FORWARD STOP
SETSCREW
ROD END
BALL JOINT
LH LOCKNUT
TURN THIS ROD TO
ADJUST NEUTRAL
UPPER LINKAGE ASSEMBLY
RH LOCKNUT
SETSCREW USED TO
ADJUST FORWARD
TRACKING
SETSCREW
LOOSEN BOLT ON
LINKAGE
Page 29
CARE AND MAINTENANCE
TILTING THE DECK (see diagram-page 31)
1. Set the parking brake.
2. Raise the foot deck into vertical position and lock into place.
3. Remove the quick release pin from the anti-buck cylinder at deck end.
4. Place the deck lift handle in the lowest cutting position.
5. Lift the rear corner of deck & pivot down hanger to disengage. (Repeat for other side.)
6. Raise deck lift handle catch, rock handle back and forth until quick release pin pulls
free with little effort.
7. Lift up on the front of the deck until deck rotates past 90 degrees. The middle hole on
the anti-buck cylinder holder will be in line with the slot on the foot deck locking device.
Use the quick release pin to secure the deck in the upright position.
LOWER AND REATTACH THE DECK (see diagram-page 31)
1. Rotate the deck back to horizontal position.
2. Stand on front of deck and align deck lift bar with deck lift handle, rock handle back and
forth until quick release pin slips through. NOTE the orientation of the holes in the bar.
The first hole is for low cutting 1" to 3", the second hole is for height cutting 3" to 5".
3. Lift the rear corner of the deck until the down hanger engages the push bar. Repeat for
other side.
4. Reattach the anti-buck cylinder.
5. Unlatch foot deck locking device and lower the foot deck back to horizontal position.
Page 30
CARE AND MAINTENANCE
FOOT DECK IN VERTICAL
POSITION
FOOT DECK LOCKING
DEVICE
DOWN HANGER IN
ENGAGED POSITION
QUICK RELEASE PIN
(deck lift handle)
LIFT CORNER OF DECK
USE THIS HANDLE TO HELP
DISENGAGE DOWN HANGER
ANTI-BUCK CYLINDER
QUICK RELEASE PIN
(anti-buck cylinder)
MIDDLE HOLE
ON ANTI-BUCK
CYLINDER
HOLDER
DECK LIFT BAR
DECK LIFT HANDLE CATCH
Page 31
CARE AND MAINTENANCE
CHECKING DECK DRIVE GEARBOX FLUID LEVEL:
The fluid level only needs to be checked if oily residue is found on the gearbox housing.
1. Rotate deck in to the upright position (see deck servicing for procedure).
2. Remove the hex head plug at the low end of the gearbox housing. (Plug closest to the
drive shaft.) The fluid level should be level with the bottom of the threaded hole.
CHANGING THE FLUID IN DECK DRIVE GEARBOX:
1. Rotate the deck into the upright position & remove drain plug from bottom of gearbox.
2, Lower deck to drain fluid.
3. When the fluid is drained from gearbox raise deck back up and reinsert the drain plug.
4. Remove hex head plug from side of gearbox and fill with Automatic Transmission Fluid
(ATF). Fill to bottom of the hole that the plug is removed from.
5. Reinstall hex head plug.
DRAIN PLUG
HEX HEAD PLUG
GEARBOX
Page 32
CARE AND MAINTENANCE
LEVELING THE DECK:
The deck comes from the manufacturer pre-leveled. If the deck does appear to be cutting unlevel follow
this procedure.
1. Set all tire pressure to correct specifications (see page 23).
2. Place machine on a level slab of concrete.
3. Move blades by hand so all the blades are pointed in the same direction (see diagram on
page 34). Measure from the blade tip (beveled edge) to the ground, all three blades. If
there is more than a 3/16" difference from one side to the other, the deck should be
leveled.
4. Remove the clevis pin from the rear of the lift spring rod, on the high side. The lift
spring rod is two parts-one threaded into the other. Turn the lift spring rod counterclockwise 2 turns. Reassemble clevis pin and remeasure. Repeat as required to
achieve a difference of no more than 3/16" from one side to the other.
5, If the deck is level side to side but high or low at the center blade, both lift spring rods
must be adjusted equal amounts. Shortening the lift spring rods will bring the center
blade up and lengthening the lift spring rods will let the center blade down.
Clevis Pin
Lift Spring Rod
Lift Spring
Tension Adjust Bolt
Page 33
DISCHARGE SIDE
CARE AND MAINTENANCE
BLADE TIP
Page 34
DECK SPINDLE BELT DIAGRAM
(Top View))
STANDARD SERVICE PARTS LIST
MODEL ZTR 6022:
BLADES: Hi-Lift: P/N 60295
Lo-Lift (standard): P/N 60293
BELTS: Serpentine Belt: P/N 60194 (48")
P/N 60186 (60")
Engine To Hydros: P/N 61101
Clutch to Driveshaft: P/N 60187
Hydrostatic Transmission Filter: P/N 7252
KOHLER AIR AND OIL FILTER PART NUMBERS:
Refer to engine manufacturers manual for recommendations regarding frequency of service
required for engine oil changes and air filter maintenance.
Protect your engine investment, use only original equipment filters.
Model ZTR 6022: 22HP Air Filter & Pre-Cleaner 78003
Engine Oil Filter 78006
IMPORTANT:
Some applications, extreme dirt conditions, or the use of a grass catcher may
require that the engine used on the Model ZTR 6022 be fitted with an OPTIONAL
Kohler fresh air filter system.
Listed below are the Kohler kit numbers required to adapt these components to the
engine. Consult your dealer or a Kohler engine service center for additional
information.
Model ZTR 6022: 22HP Check with Kohler Dealer for availability
Page 35
TROUBLESHOOTING
1. ENGINE WON'T TURN OVER
Mower blades engaged
Drive not in neutral
Blown fuse
Dead battery
Solenoid
Ignition switch
Starter
2. ENGINE WILL TURN OVER BUT WON'T START
No gas
Over or under choked
Spark plug not firing
Carburetor maladjustment
Ignition Switch
3. HARD TO START ENGINE
Fuel line clogged
Faulty fuel pump
Spark plug wire loose or grounded
Spark plug(s) faulty or improperly gapped
Electronic ignition defective
Dirty or maladjusted carburetor
-------------------------------------------------------------------------------------------------------------------------------replace fuse
---------------------------------------------------------------------------------------------------------------------charge or replace
-------------------------------------------------------------------------------------------------------------------------------consult dealer
-------------------------------------------------------------------------------------------------------------------------consult dealer
----------------------------------------------------------------------------------------------------------------------------------consult dealer
-------------------------------------------------------------------------------------------------refuel and/or clean or replace fuel filters
--------------------------------------------------------------------------------------------consult dealer for carburetor service
--------------------------------------------------------------------------------------------------------disengage blades
----------------------------------------------------------------move steering control levers to neutral "OUT " position
----------------------------------------------------------------------------------------------------------------adjust choke
---------------------------------------------------------------------------------check spark plug/condition or reset gap
---------------------------------------------------------------------reset carburetor adjustment/consult dealer
--------------------------------------------------------------------------------------------clean fuel line and check fuel filter
---------------------------------------------------------------------------------------------------------------------consult dealer
-----------------------------------------------------------------------------------check spark plug wires
--------------------------------------------------check spark plug/condition and reset gap*
---------------------------------------------------------------------------------------------------------consult dealer
------------------------------------------readjust carburetor* or consult dealer for carburetor service
4. ENGINE STARTS BUT CUTS OUT
Water in gasoline
Clogged fuel line
Vent in fuel cap plugged
Faulty fuel pump
Maladjusted carburetor
Engine dies when control levers are moved "IN"
5. ENGINE KNOCKS
Low oil level
Ignition timing off
Fuel octane too low
Over heated engine
Page 36
-----------------------------------------drain old gasoline-replace with new gasoline and/or clean carburetor bowl
-------------------------------------------------------------------------------clean carburetor bowl and or check fuel filter
----------------------------------------------------------------------------------------------------------------check vent
---------------------------------------------------------------------------------------------------------------------consult dealer
------------------------------------------------------------------------------------------------------readjust carburetor
----------------------------------------------------------------------------------------------------------------------check and add oil
---------------------------------------------------------------------------------------------------------------------consult dealer
---------------------------------------------------------------------------drain and replace with higher octane gasoline
--------------------------------------------------------------------------------------------shut off engine and allow to cool
------------------------------------------------------parking brake set -- release brake
*See engine manual for engine adjustments
TROUBLESHOOTING
6. ENGINE SOMETIMES SKIPS AT HIGHER SPEED
Incorrect ignition timing
Carburetor maladjusted
Faulty spark plugs
Bouncing off seat safety switch
7. ENGINE OVERHEATED
Air intake screen or fins clogged
Fuel mixture too lean
Oil level too low or too high
Improper ignition timing
Running engine too slow
8. ENGINE IDLES POORLY
Carburetor maladjustment
Improper spark plug gap
9. ENGINE BACKFIRES
Carburetor maladjustment
----------------------------------------------------------------------------------------------------------------Consult dealer
--------------------------------------------------------------------------------------------------------Readjust carburetor
-------------------------------------------------------------------------------Check spark plug or condition and reset gap*
---------------------------------------------------------------------------------------Slow down on rough terrain
-----------------------------------------------------------------------------------Clean Intake screen and fins
------------------------------------------------------------------------------------------------------------------Consult dealer
-----------------------------------------------------------------------------------------------------------Adjust oil level
---------------------------------------------------------------------------------------------------------------Consult dealer
----------------------------------------------------------------------------------------------------------Run engine faster
-----------------------------------------------------------------------------------------------------------Consult dealer
--------------------------------------------------------------------------------------------------Check and re-gap plug*
----------------------------------------------------------------------------------------------------------Consult dealer*
(NOTE: Always mow at full throttle setting.)
10. ENGINE RUNS BUT MOWER WON'T MOVE FORWARD
Drive belt broken or slipping
Shift linkage disconnected
Transmission shift arm disconnected
Transmission oil low
Transmission locks in free wheel position
Hydrostat oil filter plugged
Bad transmission
Gear mating transmission/gearbox disconnected
Air in transmission
Not enough tension on drive belt
11. MOWER LOSES POWER/ TRANSMISSION OVERHEATS
Hydrostat transmission oil too low or too high
Transmission damage
Transmission blowing oil out cap
12. ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat
Faulty interlock system
Bad blade spindle bearing
Deck drive belt not properly routed
Blades blocked by foreign material
-----------------------------------------------------------------------------------------------------------------------Consult dealer
----------------------------------------------------------------------------------------------------------------------------Bleed air
------------------------------------------------------------------------------------------------Re-tension or replace
-----------------------------------------------------------------------------------------------------------------Reconnect
---------------------------------------------------------------------------------------------------Reconnect
----------------------------------------------------------------------------------------------------------------------------Add oil
---------------------------------------------------------------------Put in lock position (see pg.19)
--------------------------------------------------------------------------------------------------------------Replace filter
-------------------------------------------------------------------------------Consult dealer
--------------------------------------------------------------------------------------------------------------Check
-----------------------------------------------------------------Add Oil or drain oil as needed
-----------------------------------------------------------------------------------------------------------------Consult dealer
-----------------------------------------------------------------------------Overfilled or water contaminated
------------------------------------------------------------------------------------------------------------------------Sit on seat
----------------------------------------------------------------------------------------------------------------Consult dealer
-----------------------------------------------------------------------------------------------------------Consult dealer
---------------------------------------------------------------------------------------------------------Reroute
---------------------------------------------------------------------------------------------Clean under deck
*See engine manuals for engine adjustments
Page 37
NOTES
Page 38
OWNER
INFORMATION
DATE PURCHASED
MOWER MODEL NUMBER
MOWER SERIAL NUMBER
PURCHASED FROM
Name
Address
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
FAX 316 251 4117
DATE OIL CHANGED: DATE ENGINE TUNED:
Page 39
WARNING:
The Engine Exhaust from this product contains chemicals known to
the
State of California to cause cancer, birth defects or other
reproductive harm.
Dixon® and ZTR
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
Page 40
®
are registered trademarks of Dixon Industries, Inc.
6000 Series
6022
Part No. 13090-0700
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